When you’re ready to manufacture your plastic product, the manufacturing method you choose is critical to your success. Whether you are an entrepreneur launching a new consumer product or a company seeking durable signage, understanding the distinction between custom plastic manufacturing and injection molding is crucial to your success. Whether you are an engineer prototyping components for a consumer product or fabricating a part for a construction project, the manufacturing method and process will depend on the size, complexity, and time involved.
As a leading plastic manufacturer in Las Vegas, Welch Plastics is proud to offer both custom fabrication and injection molding with capabilities to service a variety of industries from retail to construction, healthcare to electronics.
In this guide, we will help you determine which process may be best for your product and business objectives.
What Is Custom Plastic Manufacturing?
Custom plastic manufacturing (also known as custom plastic fabrication), is a very flexible way to shape flat plastic materials (sheet plastic and plastic film) into finished products, using a wide range of processes, including:
- CNC machining
- Laser cutting and laser etching
- Heat bending and thermoforming
- Solvent weld and assembly
- Line bending and vacuum forming
Custom plastic manufacturing is a great fit for prototypes, short-run production, or just a one-off, especially when precision and customization are most important.
Key Benefits of Custom Fabrication
- Unlimited Freedom Of Design
With custom fabrication, you can have any shape or configuration you can think of. Just be sure to note the raw plastic materials you will be using, either acrylic, polycarbonate, PVC, etc. Your design freedom is only limited by your imagination. Ideal for Prototyping and Low-Volume Production
Whether you are in the process of trying your hand at a new product or just producing a handful of units, custom fabrication saves you the expense and time of trying a mold tool, as it is a cost-effective process.
- Fast Turnaround Times
Not using molded tooling will drastically reduce lead times for fabrication, making it ideal for companies that must use a fast time to market strategy.
- Material Flexibility
From lightweight HDPE to crystal-clear PMMA acrylic, custom production can supply any form of material that conforms to plastic and has a range of product types.
What is Injection Molding?
Injection molding is a high-volume manufacturing process that injects molten plastic into a cavity in a tool, which is then cooled in the tool, taking the shape of the tool once solidified. Injection molding will produce parts at scale, with high consistency and high strength.
Key Benefits of Injection Molding
- Cost Effectiveness at Scale
An absolute pain when you develop a tool, but the price per part drastically decreases when you are producing at much larger runs (i.e., thousands or millions).
- Consistency and Precision at Tight Tolerances
Injection molding allows you to make the same part multiple times exactly out of a mold, and has tight tolerances, which are important in areas such as automotive, medical, and consumer electronics.
- Strength and Durability
Injection molded parts are typically stronger and harder to break by design than molded parts from any other fabrication process, due to the molecular bonding occurring during the cooling process.
- Variety of Products
Injection molding will produce anything from a small part, such as a bottle cap, to a large part, such as a dashboard in a car.
Direct Comparison: Custom Plastic Manufacturing vs. Injection Molding
| Feature | Custom Plastic Manufacturing | Injection Molding |
| Best For | Product development/low volume | custom designs High volume production |
| Upfront Cost | Low | Higher (due to mold cost) |
| Per Unit Cost | Higher per piece | Lower per piece in larger quantities |
| Lead Time | Short | Longer (what’s necessary for the molding process) |
| Design Changes | Easy and cheap | Costly, time-consuming |
| Material Options | Many options | Injection molding processes may limit options |
| Durability | Good for most applications | Superiority in consistent strength and material(s) |
When To Consider Using Custom Plastic Manufacturing
Determining whether to utilize custom plastic manufacturing or injection molding can depend on a few variables:
- Production Volume
If you are producing under 500 pieces, then custom plastic manufacturing is going to be the best method to get a reasonable price. If you are producing thousands or more, you will realize an economy of scale to justify injection molding.
- Budget
Custom plastic manufacturing has no molds or anything else as far as tooling requirements. If you are just getting started or on a smaller budget, then it would be the best option. Injection molding has high upfront fixed costs; however, this will pay for itself once you ramp up production.
- Timeline
Need product quickly? Custom plastic manufacturing can be completed quickly, but injection molding will have longer lead times and require upfront tooling. Need a repeatable product for an extended period? Injection molding can be the way to go once is tooling/molds are produced.
- Product Complexity
Custom plastic manufacturing can be used to easily and economically produce very strange and artistic designs. Injection molding is generally used for complex components that require high levels of strength, tolerance, and a repeatable manufacturing process.
Industry Examples of Activities
Custom Plastic Manufacturing Examples
- Retail Displays: Attractively durable acrylic signage, retail displays, and standees.
- Medical Equipment: Exact specification of custom holders, trays, support panel,s and shaping products.
- Customized Plastics: Ideal for architectural features: unique light diffusers and decorative panels.
Injection Molding in Practice
- Consumer Products: Phone cases, bottle caps, and kitchenware.
- Used in Automotive: Dash panel parts, handles, and switches.
- In Electronics: Cases, clips, brackets, and more.
Why use Welch Plastics as your Partner?
As a reputable plastic manufacturer in Las Vegas, we provide custom plastic fabrication and injection molding, all under one roof. Here’s why we are different:
- In-House Expertise
With over 20 years of experience, our engineers and technicians will support you from the first concept through to the completed part. Whether it is prototyping a single acrylic part or you are prepping for a large-scale injection molding run, we have the tools to help you, including the most experienced people.
- State-of-the-Art Equipment
We utilize the latest CNC routers, laser cutting, and molding machines. Each of which follows industry standards and, where applicable, conforms to ISO and ASTM specifications. This assures you that accuracy, efficiency, and quality will always be paramount in any of your projects.
- Material Expertise
Whether you need acrylic, ABS, HDPE, or polycarbonate, we carry an extensive range of plastics to meet your performance and aesthetics needs.
- Customized Services
No two projects are the same, which is why we offer consultation and engineering support to help you select which process, material, and improved design will work best in each case.
Final Thoughts: Which is Best For You?
Still not sure whether custom fabrication or injection molding is right for your project?
Use custom plastic manufacturing if:
- You are in the prototyping stages,
- You will be doing low-volume production,
- You require intricate designs or personalization,
- You have a quick turnaround with low up-front investment.
Use injection molding if:
- You need thousands (or millions) of parts,
- You need similar durability,
- You are ready to make a long-term investment in tooling so you can manage ongoing production.
Regardless of what you choose, Welch Plastics is committed to delivering quality, accuracy, and exceptional customer service.
Get Started with Welch Plastics Today!
Are you ready to bring your ideas to reality? No matter whether your project consists of a single custom acrylic prototype or an injection molding solution with high-volume production quantities, Welch Plastics is your plastic manufacturer in Las Vegas. Our team will help you evaluate the best method to produce your product — time and on budget.
Call or email us today for a free consultation to design something amazing together!
